Jeep CHEROKEE XJ Complete Workshop Repair Manual 1994

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🏷️ Basic Information Identification Make: Jeep Model: Cherokee XJ Year: 1994 Codes Chassis Code: XJ Platform: Jeep Cherokee (XJ) 👋 Introduction Market Position Vehicle Segment: Compact SUV / Off-road vehicle...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Cherokee XJ

Year:

Codes

Chassis Code:

Platform:

Jeep Cherokee (XJ)

👋 Introduction

Market Position

Vehicle Segment:

Compact SUV / Off-road vehicle

Key Selling Points:

Proven off-road capability, rugged construction, accessible maintenance

Competitive Analysis

Competitors 1994:

Toyota 4Runner, Ford Bronco II, Nissan Pathfinder, Chevrolet S-10 Blazer

Key Features

Manual Benefit:

Enables DIY repairs, saving significant costs compared to dealership service

Manual Value:

Provides professional-level technical information for accurate diagnosis and repair

📋 Manual Details

Coverage Areas

Primary Coverage:

North America

Engine Coverage:

4.0L Inline-6 (242 ci) 'High Output', 2.5L Inline-4 (150 ci)

Transmission Coverage:

AX-5 Manual, AX-15 Manual, AW-4 Automatic

Drivetrain Coverage:

2WD (RWD), 4WD (Command-Trac, Selec-Trac)

Trim Level Coverage:

All trim levels including SE, Sport, Country, Classic

Page Count

Estimated Page Count:

1500-2500 (estimated for comprehensive professional manual)

Manual Type

Type:

Workshop Service and Repair Manual

Scope:

Professional Technician Level

Language

Language:

English

Format

Digital Format:

Downloadable Digital Format (PC, Mac, Tablet, Smartphone Compatible)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshaft, timing, lubrication, cooling

Engine Performance:

Fuel delivery, ignition system, emissions control, engine management (ECU)

Transmission Manual:

AX-5, AX-15 clutch, gearbox, shifting mechanisms, driveshafts

Transmission Automatic:

AW-4 torque converter, valve body, internal components, cooling, controls

Drivetrain:

Transfer case (NV231, NP242), differentials (front and rear), axles, U-joints, CV joints

Brakes:

Front and rear brake systems (disc/drum), hydraulic lines, master cylinder, calipers, wheel cylinders, parking brake

Suspension:

Front solid axle (Dana 30), rear leaf spring suspension, shock absorbers, steering stabilizer

Steering:

Power steering system, steering gear, tie rods, steering column, steering wheel

Electrical System:

Battery, charging system (alternator), starting system (starter), lighting, instrumentation, power distribution, fuses, relays

Body And Chassis:

Body construction, chassis frame, doors, hood, tailgate, bumpers, interior trim, seats, glass, weatherstripping

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system components, operation, and service

Diagnostics:

Diagnostic trouble codes (DTCs) where applicable, diagnostic procedures for various systems

Procedures Included

Preventative Maintenance:

Oil changes, fluid checks and changes, filter replacements, tire rotations, belt inspections, spark plug replacement

Routine Repairs:

Brake pad/shoe replacement, muffler replacement, belt replacement, fluid hose replacement

Major Repairs:

Engine overhaul, transmission rebuild, differential repair, suspension component replacement

Troubleshooting:

Step-by-step diagnostic guides for common and complex issues

Electrical Diagnostics:

Wiring diagrams, component testing, circuit diagnosis

Chassis And Body:

Body panel alignment, glass replacement, interior trim removal/installation

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

Diagrams:

Detailed exploded views, wiring diagrams, schematic diagrams

Specifications:

Torque values, clearances, tolerances, fluid capacities, electrical specifications

Special Tools:

Identification and usage of specialized tools required for specific procedures

📊 Manual Specifications

File Format

Digital Format Type:

PDF (likely, optimized for digital viewing)

Searchability:

Likely text-searchable for efficient information retrieval

Print Quality

Printability:

Designed for easy printing of specific sections or the entire manual

Binding Type

Digital Access:

Downloadable File

Paper Type

Print Medium:

Digital (N/A for printed product, but implies suitability for printing)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

242 ci (4.0L) OHV V6 (High Output)

Engine Code 2:

150 ci (2.5L) OHV Inline-4

Performance

4.0L Horsepower:

177 hp @ 4500 RPM (approx.)

4.0L Torque:

220 lb-ft @ 2400 RPM (approx.)

2.5L Horsepower:

125 hp @ 4800 RPM (approx.)

2.5L Torque:

150 lb-ft @ 2400 RPM (approx.)

Fuel System

Fuel Delivery 1:

Multi-port Fuel Injection (MPI) for 4.0L

Fuel Delivery 2:

Throttle Body Injection (TBI) for 2.5L

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

20 gallons (75.7 L)

🔧 Transmission

Standard

Standard Transmission Type:

AX-5 5-speed Manual (common with 2.5L)

Optional

Optional Transmission Type 1:

AX-15 5-speed Manual (common with 4.0L)

Optional Transmission Type 2:

AW-4 4-speed Automatic

Features

Transfer Case 1:

New Process (NP) 231 Command-Trac (2WD High, 4WD High, 4WD Low, Neutral)

Transfer Case 2:

New Process (NP) 242 Selec-Trac (2WD High, Full-Time 4WD High, Part-Time 4WD High, 4WD Low, Neutral)

Axle Ratios:

3.55, 3.73, 4.10 (common depending on engine/package)

Fluid Specifications

Manual Transmission Fluid:

API GL-5, SAE 75W-90 (AX-5, AX-15)

Automatic Transmission Fluid:

Chrysler ATF+3 (or equivalent Dexron III compatible)

📐 Dimensions

Exterior

Wheelbase:

101.4 inches (2576 mm)

Length:

166.7 inches (4234 mm)

Width:

66.9 inches (1700 mm)

Height:

63.5 inches (1613 mm)

Ground Clearance:

8.1 inches (206 mm) (approx. stock)

Weights

Curb Weight Min:

3220 lbs (1460 kg) (approx.)

Curb Weight Max:

3650 lbs (1655 kg) (approx.)

Gross Vehicle Weight Rating Gvwr:

4850-5000 lbs (2200-2268 kg) (depending on configuration)

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

3-star (typical for vehicles of this era)

Active Features

Braking System:

Front disc brakes, Rear drum brakes

Four Wheel Drive:

Optional Command-Trac or Selec-Trac systems

Passive Features

Seat Belts:

Front and rear seat belts, shoulder belts

Airbags:

Driver-side airbag (standard on most models for 1994)

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player; optional CD player

Speakers:

4 or 6 speaker configurations

Driver Assistance

Cruise Control:

Optional

Connectivity

Vhf Radio:

Not applicable to this model year

🔧 Maintenance

Service Intervals

Oil Change Interval:

3000 miles (4800 km) or 3 months (severe duty) / 5000 miles (8000 km) or 6 months (normal duty)

Engine Coolant Flush:

Every 30,000 miles (48,000 km) or 24 months

Transmission Fluid Change:

Every 30,000 miles (48,000 km) for automatic, 50,000 miles (80,000 km) for manual

Transfer Case Fluid Change:

Every 30,000 miles (48,000 km)

Fluid Specifications

Engine Oil Spec:

API SG or SH, SAE 10W-30 (check manual for specific climate recommendations)

Coolant Type:

Chrysler/Mopar Antifreeze/Coolant (Green Ethylene Glycol based)

Brake Fluid Type:

DOT 3

Known Issues

Common Issue 1:

Head gasket leaks (especially on early 4.0L models, though improved by 1994)

Common Issue 2:

Cracked cylinder heads (less common on 1994 but possible)

Common Issue 3:

Water pump failures

Common Issue 4:

Leaf spring sag/breakage (due to age and load)

Common Issue 5:

Transmission cooler line leaks (AW-4)

📚 Vehicle History

Brand Heritage

Jeep Legacy:

Jeep's reputation for off-road prowess dating back to WWII

Model Evolution

Xj Introduction:

Introduced for the 1984 model year, a unibody SUV that redefined the segment

Xj Updates 1994:

1994 saw minor updates, including improved interior ergonomics and revised optional equipment packages. The 4.0L engine was further refined for better performance and emissions.

Production

Production Period:

1984-2001

Assembly Locations:

Toledo, Ohio, USA

🏆 Awards & Recognition

Recognitions

Off Road Accolades:

Consistently recognized as one of the most capable off-road vehicles of its era

Ratings

Consumer Reports Historical:

Often rated average to above average for reliability and owner satisfaction, particularly the 4.0L models.